Organic EL Device Recessed Insulating Layer Light Extraction
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Solution Overview
Problem
The existing configuration of organic electroluminescence devices has low light extraction efficiency due to increased film thickness of the resin layer, leading to increased light scattering and decreased precision in the production process, which complicates the formation of thin films and increases production time.
Innovation Solution
The device incorporates a base material with recessed and excavated portions, a transparent reflective layer, and a filling layer with optical transparency, where the filling layer is positioned within the recessed portions and excavated areas, allowing for a thinner film thickness and improved light extraction efficiency by reducing the amount of resin material applied and simplifying the production process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a resin layer is formed to fill the recessed portion between reflective electrode and organic layer, then the light extraction efficiency is improved, but the film thickness increases and production time increases
Solution Approach 1:
The patent applies preliminary action by forming the excavated portion in the insulating layer before depositing the reflective layer. This pre-prepared structure allows the reflective layer to be directly formed in the recessed area without requiring subsequent resin filling, thereby reducing production steps and time while maintaining light extraction efficiency
Solution Approach 2:
The patent extracts the resin filling step from the production process by using an excavated portion structure. The insulating layer itself is removed in the excavated area to create a recess that naturally holds the reflective layer, eliminating the need for additional resin material and simplifying the manufacturing process
2Manufacturing precision
If the film thickness of the resin layer is increased, then the recessed portion is adequately filled, but light scattering in lateral direction increases and light extraction efficiency decreases
Solution Approach 1:
The patent applies local quality by creating an excavated portion with specific depth and width ratios that are optimized for the local light extraction function. The excavated portion has a depth of 0.5-2.0 μm and width of 5-20 μm, providing adequate reflective layer positioning without excessive resin thickness that would cause light scattering
Solution Approach 2:
The patent changes the physical parameters of the insulating layer by creating an excavated portion with controlled depth and width. This parameter modification allows the reflective layer to be positioned at the optimal depth without requiring thick resin filling, thereby preventing light scattering while ensuring proper filling
3Quantity of substance
If the amount of resin material applied is increased, then the recessed portion is fully filled, but the forming precision decreases
Solution Approach 1:
The patent extracts unnecessary resin material by creating an excavated portion that removes insulating layer material. This reduces the total resin material required from 1-3 μm to a minimal amount, thereby improving forming precision and reducing material waste
Solution Approach 2:
The patent applies preliminary action by pre-removing the insulating layer in the excavated portion area before resin application. This preliminary preparation ensures that minimal resin material is needed and allows for precise control of the filling process, improving overall manufacturing precision
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration enhances light extraction efficiency and reduces production time by minimizing film thickness variations and resin application, resulting in a more efficient and cost-effective organic electroluminescence device.
Implementation Method 1
a light reflective layer configured to reflect light emitted from the plurality of organic EL elements to the support substrate side
Implementation Method 2
a filling layer having optical transparency and filling the inside of the recessed portion
Data Source
AI summary
An organic EL device of one aspect of the disclosure includes: a base material; an insulating layer provided with a recessed portion on an upper face thereof; and a light-emitting element including a reflective layer provided on at least a surface of the recessed portion, a filling layer having optical transparency and filling the inside of the recessed portion with the reflective layer interposed between the filling layer and the recessed portion, a first electrode having optical transparency and provided on at least an upper layer side of the filling layer, an organic layer containing at least a light-emitting layer provided on an upper layer of the first electrode, a second electrode having optical transparency and provided on an upper layer side of the organic layer, and an edge cover layer covering at least an end portion of the first electrode, wherein the organic electroluminescence device includes a plurality of unit light emitting regions separated from one another, an excavated portion is provided in the insulating layer between adjacent unit light emitting regions, and at last the filling layer is provided inside the excavated portion.